Contributions of Microelectrochemical Scanning Techniques for the Efficient Detection of Localized Corrosion Processes at the Cut Edges of Polymer-Coated Galvanized Steel.

Spatially resolved information on corrosion reactions operating at the cut edges of coated metals can be obtained using microelectrochemical scanning techniques using a suitable selection of operation modes and scanning probes. The scanning vibrating electrode technique (SVET) provides current density maps with a spatial resolution of the order of the dimensions of the sample, which allows the temporal evolution of the corrosion reactions to be followed over time. This leads to the identification and localization of cathodic and anodic sites, although the technique lacks chemical specificity for the unequivocal identification of the reactive species. The application of scanning electrochemical microscopy (SECM) was previously limited to image cathodic reaction sites, either due to oxygen consumption in the amperometric operation or by the alkalinisation of the electrolyte in potentiometric operation. However, it is shown that anodic sites can be effectively monitored using an ion-selective microelectrode (ISME) as a probe. The ISME probes detected differences in the local concentrations of Zn2+ and OH- ions from the cut edges of a complete coil coating system compared to the same system after the polymeric layers were removed. In this way, it has been shown that the inhibitor loading in the polymer layers effectively contributes to reducing the corrosion rates at the cut edge, thus helping to extend the useful life of the sacrificial galvanized layer bonded directly to the steel matrix. Additionally, these two probe configurations can be integrated into a multi-electrode tip for potentiometric operation to simultaneously monitor localized changes in pH values and metal ion dissolution in a single scan. Spatial and temporal distributions were further investigated using different rastering procedures, and the potential of constructing pseudomaps for 2D-imaging is described.

Phase equilibria among η-Fe2Al5 and its higher-ordered phases.

Phase equilibria among the η-Fe2Al5 phase and its higher-ordered phases with the η framework structure were determined experimentally. The solubility range of the η phase at elevated temperature does not differ remarkably from that in previous studies, but this phase is found to undergo complicated phase transformations upon cooling. Four phases are present, namely η', η", η"' and η m, with higher-order atomic orderings in the c-axis chain sites of the orthorhombic crystal structure of the parent η phase. The η" and η"' phases form on the Al-poor and Al-rich sides, respectively, in equilibrium with the ζ-FeAl2 phase below ~415°C and θ-Fe4Al13 phase below ~405°C. The η' and η m phases become stable below 312°C and 343°C with the peritectoid reactions η' → η m + Î·"' and η m → η + Î·", respectively. The η phase is not stable below 331°C with the eutectoid reaction of η m + Î·"' → η. On the basis of these findings, we unraveled the phase equilibria among the η-Fe2Al5 phase and its higher-ordered phases with the η framework structure.

Impact of biofilm in the maturation process on the corrosion behavior of galvanized steel: long-term evaluation by EIS.

In this study, the effect of biofilm in the maturation process on the corrosion behavior of galvanized steel was investigated in a model of a recirculating water system over 6 months. Electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization methods were used to determine the corrosion behavior of galvanized steel. The biofilm and corrosion products on the galvanized steel surfaces were investigated by using scanning electron microscopy (SEM) and energy dispersive X-ray spectrometry (EDS). EIS results showed that the structure of the biofilm changed during the maturation process over time and the altering structure of the biofilm affects the corrosion behavior of galvanized steel. Also, EIS analyses validated that the biofilm has a dynamic and complex structure. The data obtained from SEM and macroscopic images indicated that EIS is an effective method for monitoring the biofilm-development process.

Isolation of a sulfide-producing bacterial consortium from cooling-tower water: Evaluation of corrosive effects on galvanized steel.

Sulfidogenic Clostridia and sulfate reducing bacteria (SRB) often cohabit in nature. The presence of these microorganisms can cause microbially influenced corrosion (MIC) of materials in different ways. To investigate this aspect, bacteria were isolated from cooling tower water and used in corrosion tests of galvanized steel. The identity of the isolates was determined by comparative sequence analysis of PCR-amplified 16S rDNA gene fragments, separated by denaturing gradient gel electrophoresis (DGGE). This analysis showed that, in spite of the isolation process, colonies were not pure and consisted of a mixture of bacteria affiliated with Desulfosporosinus meridiei and Clostridium sp. To evaluate the corrosive effect, galvanized steel coupons were incubated with a mixed culture for 4, 8, 24, 72, 96, 168, 360 and 744 h, along with a control set in sterile culture medium only. The corrosion rate was determined by weight loss, and biofilm formation and corroded surfaces were observed by scanning electron microscopy (SEM). Although the sulfide-producing bacterial consortium led to a slight increase in the corrosion of galvanized steel coupons, when compared to the previous studies it can be said that Clostridium sp. can reduce the corrosive effect of the Desulfosporosinus sp. strain.

The Effect of Addition Potassium Permanganate on Bond Strength of Hot-Dip Galvanized Plain Bars with Cement Paste.

In this paper, the effect of gradually increasing amounts of KMnO4 (10-4, 10-3, 10-2 mol·L-1) in cement paste on the bond strength of a plain hot-dip galvanized steel bar was evaluated. The open-circuit potential of HDG samples in cement paste with various additions of MnO4- was monitored in order to follow a transfer of zinc from activity to passivity. Furthermore, the influence of the addition of these anions on the physicochemical properties of normal-strength concrete or cement paste was evaluated by means of hydration heat measurements, X-ray diffraction analysis, and compressive strength. The effective concentration of MnO4- anions prevents the corrosion of the coating with hydrogen evolution and ensures that the bond strength is not reduced by their action, which was determined to be 10-3 mol·L-1. Lower additions of MnO4- anions (10-4 mol·L-1) are ineffective in this respect. On the other hand, higher additions of MnO4- anions (10-2 mol·L-1), although they ensure the corrosion of the coating in fresh concrete without hydrogen evolution, but affect the hydration process of the cement paste that was demonstrated by slight water separation.

Atmospheric corrosion and impact toughness of steels: Case study in steels with and without galvanizing, exposed for 3 years in Rapa Nui Island.

We studied atmospheric corrosion on Rapa Nui Island, using galvanized and non-galvanized SAE 1020 steel samples exposed on racks. We also added Charpy samples of both materials to directly determine the effect of corrosion rate on these materials' impact toughness. The results indicated a correlation between corrosion rate and toughness loss in the studied materials. In the corrosion study, we could also demonstrate the effect from increased insular population growth on contaminants which aid atmospheric corrosivity. Results showed that atmospheric SO2 has tripled compared with similar corrosion studies done 20 years ago (Mapa Iberoamericano de Corrosión, MICAT), increasing corrosion rates. Our results show how human factors can influence changes in environmental variables that strengthen corrosion.

Mitigation of galvanized steel biocorrosion by Pseudomonas aeruginosa biofilm using a biocide enhanced by trehalase.

Pseudomonas aeruginosa is a facultative bacterium that is pathogenic. It is ubiquitous in the environment including air handling systems. It causes microbiologically influenced corrosion (MIC) aerobically and anaerobically. In this work, P. aeruginosa was grown as a nitrate reducing bacterium (NRB) in Luria-Bertani medium with KNO3 at 37 °C. Trehalase, an enzyme which plays a crucial role in biofilm formation was found to enhance the treatment of P. aeruginosa biofilm and its MIC against galvanized steel by tetrakis-hydroxymethyl phosphonium sulfate (THPS) green biocide. After a 7-d incubation, 30 ppm (w/w) trehalase reduced sessile cell count by 0.8-log, and it also reduced galvanized steel weight loss by 14%, compared to 2.3-log and 39%, respectively for the 30 ppm THPS treatment. The combination of 30 ppm THPS + 30 ppm trehalase reduced sessile cell count further by 0.1-log and weight loss by 13% compared to using THPS alone. Electrochemical corrosion measurements supported weight loss results. The injection of 20 ppm riboflavin into a 3-d P. aeruginosa broth failed to accelerate the corrosion rate, suggesting that nitrate reducing P. aeruginosa MIC of galvanized steel did not belong to extracellular electron transfer-MIC, because Zn was hydrolyzed after the microbe damaged the passive film.

Effects of Ambient Temperature and State of Galvanized Layer on Corrosion of Galvanized Steel in High-Humidity Neutral Atmosphere.

Galvanized steel is a cost-effective and corrosion-resistant material with high strength, making it a popular choice for various engineering applications. In order to investigate the effects of ambient temperature and galvanized layer state on the corrosion of galvanized steel in a high-humidity neutral atmosphere environment, we placed three types of specimens (Q235 steel, undamaged galvanized steel, damaged galvanized steel) in a neutral atmosphere environment with a humidity of 95% at three different temperatures (50 °C, 70 °C, and 90 °C) for testing. The corrosion behavior of specimens under simulated high-temperature and high-humidity conditions was studied using weight changes, macroscopic and microscopic observations, and analysis of the corrosion products of the specimens before and after corrosion. Emphasis was placed on examining the effects of temperature and damage to the galvanized layer on the corrosion rate of the specimens. The findings indicated that damaged galvanized steel retains good corrosion resistance at 50 °C. However, at 70 °C and 90 °C, the damage to the galvanized layer will accelerate the corrosion of the base metal.

Molecular Understanding of the Interfacial Interaction and Corrosion Resistance between Epoxy Adhesive and Metallic Oxides on Galvanized Steel.

The epoxy adhesive-galvanized steel adhesive structure has been widely used in various industrial fields, but achieving high bonding strength and corrosion resistance is a challenge. This study examined the impact of surface oxides on the interfacial bonding performance of two types of galvanized steel with Zn-Al or Zn-Al-Mg coatings. Scanning electron microscopy and X-ray photoelectron spectroscopy analysis showed that the Zn-Al coating was covered by ZnO and Al2O3, while MgO was additionally found on the Zn-Al-Mg coating. Both coatings exhibited excellent adhesion in dry environments, but after 21 days of water soaking, the Zn-Al-Mg joint demonstrated better corrosion resistance than the Zn-Al joint. Numerical simulations revealed that metallic oxides of ZnO, Al2O3, and MgO had different adsorption preferences for the main components of the adhesive. The adhesion stress at the coating-adhesive interface was mainly due to hydrogen bonds and ionic interactions, and the theoretical adhesion stress of MgO adhesive system was higher than that of ZnO and Al2O3. The corrosion resistance of the Zn-Al-Mg adhesive interface was mainly due to the stronger corrosion resistance of the coating itself, and the lower water-related hydrogen bond content at the MgO adhesive interface. Understanding these bonding mechanisms can lead to the development of improved adhesive-galvanized steel structures with enhanced corrosion resistance.

Corrosion Resistance of Zinc and Zinc-Aluminum-Magnesium Coatings in Atmosphere on the Territory of Russia.

Zinc-coated carbon steel is commonly used in the construction of buildings, infrastructure objects such as roads and bridges, automotive production, etc. Coatings based on zinc-aluminum-magnesium alloys that may have better corrosion resistance than zinc have been developed. The coatings made of the new alloys have been available on the market for a shorter period of time than conventional zinc coatings. This paper presents data on the corrosion resistance of zinc and zinc-aluminum-magnesium coatings on carbon steel obtained by tests in four locations in Russia with marine and non-marine atmospheres. Four one-year exposures at the beginning of each season and two-year tests were performed. It is shown that the corrosion resistance of the coatings depends significantly on the beginning of the exposure. The categories of atmosphere corrosivity in relation to the coatings were determined at each location. Based on the dose-response function (DRF) for zinc developed for the territory of Russia, DRFs for the coatings were obtained. A match between the categories of atmosphere corrosivity determined by the first-year corrosion losses and estimated from the values of corrosion losses calculated using the DRF is shown. Based on the data of two-year tests, the variation in the corrosion rate over time is obtained. The corrosion rates of the coatings in the territory of Russia are compared to the corrosion rates of coatings observed in various locations around the world. An approximate estimate of the service life of the coatings at the test sites is given.

Stability of arsenic(â ¢, â ¤) in galvanized steel pipe scales coexisting with colloidal polystyrene microplastics under drinking water conditions.

The stability of metalloid arsenic (As(Ⅲ)) and As(V) in corrosion scales of drinking water distribution systems (DWDS) is closely related to drinking water safety. The effects of colloidal microplastics entering the DWDS on the stability of As(Ⅲ) and As(V) have not been understood. This study investigated the migration and transformation behaviors of As (Ⅲ) and As(V) in the galvanized steel pipe scales employing speciation simulation and sequential extraction methods. The stability of As(Ⅲ) and As(V) in the pipe scales coexisting with colloidal polystyrene microplastics (CPMPs) under drinking water conditions was studied for the first time from the release behaviors and form distributions. Finally, the optimum water quality conditions for As(Ⅲ) and As(V) fixation were summarized. The existing forms of As(Ⅲ) and As(V) under different pH conditions, the competitive action of anions, and the hydrolysis of cations all would significantly affect the stability of As(Ⅲ) and As(V). Sequential extraction method results revealed that the content of As fractions increased in different forms after the pipe scales adsorbed As(Ⅲ) and As(V). The contents of As and iron (Fe) in the form of residual fractions increased in the presence of CPMPs. The effect of three cations on the stability of As(Ⅲ) and As(V) was Fe3+ > Zn2+ > Ca2+. Neutral to weak alkalescence, proper Cl- and cation concentrations were conducive to the fixation of As in DWDS. Notably, the presence of CPMPs could increase the stability of As(Ⅲ) and As(V) in corrosion scales, thus reducing the risk of metalloid As release in DWDS.

Formation of Composite Coatings on Galvanized Steel from Organosilane Solutions Using Electrophoresis and Sol-Gel Technology.

New hybrid composite coatings (HCCs) on hot-dip galvanized steel (HDGS) were obtained using electrophoresis (cathodic polarization (CP)) and sol-gel technology. For this purpose, a technique for the preparation of a cationic precursor based on TiCl4 and aminopropyltriethoxysilane was developed. Electrophoresis of the charged particles of the precursor and organosilanes promotes the production of denser sol-gel coatings with improved adhesion. Using scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS) and electrochemical impedance spectroscopy (EIS) methods, the formation mechanism and protective properties of HCC on galvanized steel were investigated.

Atmospheric corrosion maps as a tool for designing and maintaining building materials: A review.

Atmospheric corrosion maps can be used to conduct a fast and graphical assessment of material deterioration in specific geographic environments. These maps are a key tool for selecting the most adequate materials in terms of corrosion resistance, maintenance, and cost-efficiency in outdoor constructions. Several studies have evaluated the effects of environmental factors and pollutants on building materials at local, regional, national, and international levels. However, not enough atmospheric corrosion maps are readily available, possibly due to the complexity of the variables that should be considered to construct them, which include weather, meteorological, and pollution-related factors that vary in space and time. This article presents a thorough literature review of atmospheric corrosion maps published between 1971 and 2021 mainly indexed in the Scopus database. It is complemented with a detailed review of books, journals, and projects by research centers that focuses on the methodologies, parameters, and tools that have been used to construct said maps. Most of the available maps are outdated, which highlights the need for new maps that reflect recent global changes in atmospheric pollution and temperature that can intensify metal deterioration in some places.

Influence of Current on Soil Corrosion of Galvanized Steel of Grounding Grids.

Grounding grid materials are vulnerable to soil corrosion, which is detrimental to the safe operation of the grounding grids and even lead to serious accidents of power transmission. In this paper, galvanized steel was used as the typical grounding grid material which was buried in the soil and then electrified with AC and DC current for two weeks. The corroded samples under different current conditions were characterized and compared. The experimental results show that the corrosion degree of galvanized steel gradually aggravated with the increasing of the current, especially under DC current. Further, the mechanism of the influence of current on soil corrosion is explored. It is found that under the same magnitude of current, the corrosion degree of galvanized steel under DC current is greater than that under AC current.

The Influence of Graded Amount of Potassium Permanganate on Corrosion of Hot-Dip Galvanized Steel in Simulated Concrete Pore Solutions.

This paper evaluates the amount of KMnO4 in simulated concrete pore solution (pH 12.8) on the corrosion behaviour of hot-dip galvanized steel (HDG). In the range of used MnO4- (10-4, 10-3, 10-2 mol·L-1), corrosion behaviour is examined with regard to hydrogen evolution and composition (protective barrier properties) of forming corrosion products. The corrosion behaviour of HDG samples is evaluated using Rp/Ecorr and EIS. The composition of corrosion products is evaluated using SEM, XRD, XPS and AAS. The effective MnO4- ion concentration to prevent the corrosion of coating with hydrogen evolution is 10-3 mol·L-1; lower concentrations only prolong the time to passivation (corrosion with hydrogen evolution). The highest used MnO4- concentration ensures corrosion behaviour without hydrogen evolution but also leads to the formation of less-protective amorphous corrosion products rich in MnII/MnIII phases.

The influence of Ag-Cu ions on natural biofilms of variable ages: Evaluation of MIC.

In this study, the biofilms at different ages formed on galvanized steel coupons in a simulating cooling tower water system were exposed to the Ag-Cu ions over 504 h and the changes in the structure of the biofilms were investigated using electrochemical, microbiological, and surface analyses. The effect of the Ag-Cu ions on the structure of the natural biofilm during the maturation process was evaluated for the first time in this study. Exposure to Ag-Cu ions changed the structure of the biofilm, reducing the concentration of carbohydrates in EPS, causing the shedding from the biofilm by disrupting/making weakening the integrity of the biofilm. After exposure to Ag-Cu ions, the biofilm turned into a heterogeneous, fissured-porous and sandy structure. In addition, in the absence of the ions and after exposure to the ions, the MIC behavior of galvanized steel with natural biofilm at different ages was evaluated using electrochemical and gravimetric tests. It was determined that the galvanized steel suffered to MIC and exposure to Ag-Cu ions increased the corrosion rate of it. Therefore, using of Ag-Cu ions at maximum concentration values (0.1 ppm Ag and 1.3 ppm Cu) suggested by EPA is not recommended to prevent MIC problem in cooling tower systems.

Effect of Sulfate Ions on Galvanized Post-Tensioned Steel Corrosion in Alkaline Solutions and the Interaction with Other Ions.

Zinc protection of galvanized steel is initially dissolved in alkaline solutions. However, a passive layer is formed over time which protects the steel from corrosion. The behavior of galvanized steel exposed to strong alkaline solutions (pH values of 12.7) with a fixed concentration of sulfate ions of 0.04 M is studied here. Electrochemical measurement techniques such as corrosion potential, linear polarization resistance and electrochemical impedance spectroscopy are used. Synergistic effects of sulfate ions are also studied together with other anions such as chloride Cl− or bicarbonate ion HCO3− and with other cations such as calcium Ca2+, ammonium NH4+ and magnesium Mg2+. The presence of sulfate ions can also depassivate the steel, leading to a corrosion current density of 0.3 µA/cm2 at the end of the test. The presence of other ions in the solution increases this effect. The increase in corrosion current density caused by cations and anions corresponds to the following orders (greater to lesser influence): NH4+ > Ca2+ > Mg2+ and HCO3− > Cl− > SO42−.

Microstructure Evolution and Strengthening Mechanism of Galvanized Steel/Mg Alloy Joint Obtained by Ultrasonic Vibration-Assisted Welding Process.

A novel ultrasonic vibration-assisted welding (UVAW) process was used to achieve reliable joining of galvanized steel and Mg alloy. The effects of the UVAW technique on the microstructure and mechanical properties of galvanized steel/Mg alloy weldment were studied in detail. The introduction of ultrasonic vibration can ameliorate the wetting of welds and eliminate porosity defects. A refined microstructure of the fusion welding zone with an average grain size of 39 ± 1.7 µm was obtained and attributed to cavitation and acoustic streaming caused by the UVAW process. The grain refinement led to an increase in the microhardness and joining strength of the galvanized steel/Mg alloy weldment. Under the ultrasonic power of 0.9 kW and a current of 65 A, the maximum joining strength of the ultrasound-treated galvanized steel/Mg alloy joint was 251 ± 4.1 MPa, which was a 14.6% increase over the joint without ultrasonic treatment.

Microstructure and Fatigue Behaviors of Dissimilar A6061/Galvannealed Steel Joints Fabricated by Friction Stir Spot Welding.

The microstructures, tensile shear properties, and tensile shear fatigue properties of dissimilar A6061/Galvannealed steel joints fabricated by friction stir spot welding (FSSW) were investigated. Fe4Al13 phases form as the intermetallic compound (IMC) layer at the joint interface between the A6061 matrix and the galvannealed layer consisting of FeZn7, Fe, and Zn. At the edge of the joint, the stirred layer in which the A6061 matrix and the galvannealed layer are stirred also forms. Moreover, the solidified part of the residual melt discharged from the joint area forms at the outer peripheries of the joint. In this study, FSSW was conducted for two total welding durations: 9 and 10 s. Although the thickness of the remaining A6061 sheet in the welded area decreased with an increase in the welding time, the effects of the total welding time on tensile shear and tensile shear fatigue properties were negligible. A fatigue fracture occurred in the A6061 matrix and at the joint interface at the high cycle fatigue region and the low cycle fatigue region, respectively. In the case of the interfacial fracture, the crack was generated in the solidified part of the residual melt or at the interface between the solidified part and the stirred layer.

Biopolymeric Anticorrosion Coatings from Cellulose Nanofibrils and Colloidal Lignin Particles.

This study presents a process for preparation of cellulose-lignin barrier coatings for hot-dip galvanized (HDG) steel by aqueous electrophoretic deposition. Initially, a solution of softwood kraft lignin and diethylene glycol monobutyl ether was used to prepare an aqueous dispersion of colloidal lignin particles (CLPs) via solvent exchange. Analysis of the dispersion showed that it comprised submicron particles (D = 146 nm) with spherical morphologies and colloidal stability (ζ-potential = -40 mV). Following successful formation, the CLP dispersion was mixed with a suspension of TEMPO-oxidized cellulose nanofibers (TOCN, 1 and 2 g·L-1) at a fixed volumetric ratio (1:1, TOCN-CLPs), and biopolymers were deposited onto HDG steel surfaces at different potentials (0.5 and 3 V). The effects of these variables on coating formation, dry adhesion, and electrochemical properties (3.5% NaCl) were investigated. The scanning electron microscopy results showed that coalescence of CLPs occurs during the drying of composite coatings, resulting in formation of a barrier layer on HDG steel. The scanning vibrating electrode technique results demonstrated that the TOCN-CLP layers reduced the penetration of the electrolyte (3.5% NaCl) to the metal-coating interface for at least 48 h of immersion, with a more prolonged barrier performance for 3 V-deposited coatings. Additional electrochemical impedance spectroscopy studies showed that all four coatings provided increased levels of charge transfer resistance (Rct)-compared to bare HDG steel-although coatings deposited at a higher potential (3 V) and a higher TOCN concentration provided the maximum charge transfer resistance after 15 days of immersion (13.7 cf. 0.2 kΩ·cm2 for HDG steel). Overall, these results highlight the potential of TOCN-CLP biopolymeric composites as a basis for sustainable corrosion protection coatings.